high efficiency. multi-functional machining of aluminium

TOOL NEWS

AlimasterNew

B264G

Series Expansion

2021.9 Update

High Efficiency. Multi-functional Machining of Aluminium AlloysNew DLC coated type added to the range for even better welding resistance.

High Efficiency Machining of Aluminium Alloys

1

AlimasterNew

A3SA

A3SARB

APMXCurved Edge

Helical internal through coolant holes, together with an optimised cutting edge geometry enables highly efficient machining.


Iregular Helix and Curved Flute Exit Geometry Radius Flute Exit Geometry

Helical Through Coolant Holes

Strengthened Centre Cutting Edges

Ideal Flute Geometry

Suppresses chatter to enable excellent surface finishes.

Chip discharge during plunging, ramping and grooving have been significantly improved, for stable, high efficiency cutting.Helical holes maintain a stable coolant supply even after re-grinding.

Optimised centre cutting edges provide strength and reliability even during plunging.

The cross sectional geometry of the flutes is perfect for efficient chip discharge and prevents chip jamming commonly associated with high feed machining of aluminium.

Square End Mill, 3 Flute

Radius End Mill, 3 Flute

2

0 3 6 9 12

A1050

A5052

A6063

A7075

DLC3SA

DLC3SARB

ap = 12 mm ap = 3 mm

Square End Mill, 3 Flute

Radius End Mill, 3 Flute

Alu

min

ium

Allo

ys

Depth of Cut ap (mm)

DLC Coating

DLC Coating

Uncoated

Uncoated

<Cutting Conditions>Tool : DC = ø12 mmCutting Speed : vc = 452m/minFeed per Tooth : fz = 0.1mm/t.Overhang Length : 36mmCutting Mode : Dry Cutting

By adopting a unique DLC coating with excellent adhesion and welding resistance, cutting friction is reduced thereby provides extra stability and efficiency. Additionally wet or dry cutting is possible for slot milling and contouring.

DLC CoatingHigh Efficiency & Economy

Dry Slot Milling - Comparison when Machining Different MaterialsThe excellent welding resistance and chip evacuation properties enables high efficiency slot milling even at large depths of cut.

DLC coatings may differ naturally in colour. This has no effect on quality or performance.

* Air blow both internal and external is used to effectively evacuate chips.

Chip Adhesion

Chip Adhesion

Chip Adhesion

3

12000 452 3600 0.1 12 1212000 452 1800 0.05 12 1212000 452 1800 0.05 –12000 452 3600 0.1 12 3.6

(mm)


Cutting Performance

<Cutting Conditions>Workpiece Material : A7050Tool : DLC3SA120N36CCutting Mode : Dry CuttingMachine : Vertical M/C

Cutting ModeRevolution

n(min-1)

Cutting Speedvc

(m/min)

Feed Ratevf

(mm/min)

Feed per Toothfz

(mm/t.)

Depth of Cutap

Width of Cutae

Slot Milling

Ramping : 3°

Helical Milling Pitch 2Pocket Milling

Pocket Milling100ｘ45mm (ap=12mm)

Helical Millingø20mm, Hole Depth 12mm

Wall Surface

With DLC Coating - Example of Dry Machining A7075 MaterialMulti-functional dry machining is possible.

* Air blow both internal and external is used to effectively evacuate chips.

Excellent Chip Evacuation

4

New

12000 452 3600 0.1 12 1212000 452 1800 0.05 12 1212000 452 1800 0.05 –12000 452 3600 0.1 12 3.6

25500.32

30200.38

35000.44

Alimaster

<Cutting Conditions>Workpiece Material : A7050Tool : A3SA120N36C DC = ø12 mmCutting Speed : vc = 100m/minDepth of Cut : ap = 12mmOverhang Length : 36mmCutting Mode : Internal Coolant (Water-soluble Coolants)

Feed Rate (mm/min)

Feed per Tooth (mm/t.)

Conventional A

Conventional B

Breakage due to chip clogging

Breakage due to chip clogging

Uncoated Type - Slot Machining A7050 MaterialUtilising internal coolant and an optimised cutting edge geometry enables double the efficiency levels of conventional products.

Good Wall Surface

Good Wall Surface

Good Wall Surface Good Wall Surface

Cutting ModeRevolution

n(min-1)

Cutting Speedvc

(m/min)

Feed Ratevf

(mm/min)

Feed per Toothfz

(mm/t.)

Depth of Cutap

Width of Cutae

Slot Milling

Ramping : 3°

Helical Milling Pitch 2Pocket Milling

5

New

New

10400.13

12800.16

15200.19

Alimaster

Alimaster


Cutting Performance

<Cutting Conditions>Workpiece Material : A7050Tool : A3SA120N36C DC = ø12 mmCutting Speed : vc = 300m/minDepth of Cut : ap = 12mmOverhang Length : 36mmCutting Mode : Internal Coolant (Water-soluble Coolants)

Feed Rate (mm/min)

Feed per Rev. (mm/rev)

Conventional Fracture

After F=1520 mm/min, fz=0.19 mm/rev Plunging

Uncoated Type - Plunge Machining A7050 MaterialHigher feed rates than conventional products brings greater machining efficiencies.

Strengthened Centre Cutting Edges

6

DC =APMX =LU =DN =

LF =DCON =

e

DLC3SA

DC APMX LU DN LF DCON

DLC3SA120N36C 12 18 36 11.4 80 12 3 a

DLC3SA160N48C 16 24 48 15.4 90 16 3 a

DLC3SA200N55C 20 30 55 18 100 20 3 a

DLC3SA250N55C 25 37.5 55 23 100 25 3 a

DC=12 DC>12 0- 0.020

0- 0.030

0- 0.011

0- 0.013

APMXLU

DC

DC

ON

LF

DN

APMX

37.5°

Carbon Steel, Alloy Steel, Cast Iron (<30HRC)

Tool Steel, Pre-hardened Steel,Hardened Steel (<45HRC)

Hardened Steel (<55HRC)

Hardened Steel (>55HRC)

Austenitic Stainless Steel

Titanium AlloyHeat Resistant Alloy Copper Alloy Aluminium Alloy

a : Inventory maintained in Japan.

Cutting Dia.Depth of Cut Max.Usable LengthNeck Dia.

Functional LengthConnection Dia.

* Number of Flutes

End mill, Short cut length, 3 flute, with multiple internal through coolant holes

Order Number No.F

Stoc

k

12<DCON<16 20<DCON<25

*

CurvedEdge

a

a

Stability and reliability even when slotting, ramping and plunging.DLC coating aids in providing excellent chip evacuation.

7

e

DLC3SARB

DC RE APMX LU DN LF DCON

DLC3SARB120R100N36C 12 1 18 36 11.4 80 12 3 a

DLC3SARB120R200N36C 12 2 18 36 11.4 80 12 3 a

DLC3SARB120R300N36C 12 3 18 36 11.4 80 12 3 a

DLC3SARB160R200N48C 16 2 24 48 15.4 90 16 3 a

DLC3SARB160R300N48C 16 3 24 48 15.4 90 16 3 a

DLC3SARB160R400N48C 16 4 24 48 15.4 90 16 3 a

DLC3SARB200R200N55C 20 2 30 55 18 100 20 3 a

DLC3SARB200R300N55C 20 3 30 55 18 100 20 3 a

DLC3SARB200R400N55C 20 4 30 55 18 100 20 3 a

DLC3SARB250R200N55C 25 2 37.5 55 23 100 25 3 a

DLC3SARB250R300N55C 25 3 37.5 55 23 100 25 3 a

DLC3SARB250R400N55C 25 4 37.5 55 23 100 25 3 a

DLC3SARB250R500N55C 25 5 37.5 55 23 100 25 3 a

(mm)

DC=12 DC>12 0- 0.020

0- 0.030

0- 0.011

0- 0.013

DC =RE =APMX =LU =

DN =LF =DCON =

37.5°

APMX

DC

DC

ON

LF

RE

DN

LU

APMX









Order Number No.F

Stoc

k*

* Number of Flutes

Corner radius end mill, Short cut length, 3 flute, with multiple internal through coolant holes

CurvedEdge

a

a

Stability and reliability even when slotting, ramping and plunging.DLC coating aids in providing excellent chip evacuation.

12<DCON<16 20<DCON<25

Cutting Dia.Corner RadiusDepth of Cut Max.Usable Length

Neck Dia.Functional LengthConnection Dia.

8

DC =APMX =LU =DN =

LF =DCON =

e

A3SA

DC APMX LU DN LF DCON

A3SA120N36C 12 18 36 11.4 80 12 3 a

A3SA160N48C 16 24 48 15.4 90 16 3 a

A3SA200N55C 20 30 55 18 100 20 3 a

A3SA250N55C 25 37.5 55 23 100 25 3 a

DC=12 DC>12 0- 0.020

0- 0.030

0- 0.011

0- 0.013

APMXLU

DC

DC

ON

LF

DN

APMX

37.5°







Cutting Dia.Depth of Cut Max.Usable LengthNeck Dia.

Functional LengthConnection Dia.

* Number of Flutes

End mill, Short cut length, 3 flute, with multiple internal through coolant holes

Order Number No.F

Stoc

k

12<DCON<16 20<DCON<25

*

CurvedEdge

a

a

Stability and reliability even when slotting, ramping and plunging.The cross sectional geometry of the flutes is perfect for efficient chip discharge.

9

e

A3SARB

DC RE APMX LU DN LF DCON

A3SARB120R100N36C 12 1 18 36 11.4 80 12 3 a

A3SARB120R200N36C 12 2 18 36 11.4 80 12 3 a

A3SARB120R300N36C 12 3 18 36 11.4 80 12 3 a

A3SARB160R200N48C 16 2 24 48 15.4 90 16 3 a

A3SARB160R300N48C 16 3 24 48 15.4 90 16 3 a

A3SARB160R400N48C 16 4 24 48 15.4 90 16 3 a

A3SARB200R200N55C 20 2 30 55 18 100 20 3 a

A3SARB200R300N55C 20 3 30 55 18 100 20 3 a

A3SARB200R400N55C 20 4 30 55 18 100 20 3 a

A3SARB250R200N55C 25 2 37.5 55 23 100 25 3 a

A3SARB250R300N55C 25 3 37.5 55 23 100 25 3 a

A3SARB250R400N55C 25 4 37.5 55 23 100 25 3 a

A3SARB250R500N55C 25 5 37.5 55 23 100 25 3 a

(mm)

DC=12 DC>12 0- 0.020

0- 0.030

0- 0.011

0- 0.013

DC =RE =APMX =LU =

DN =LF =DCON =

37.5°

APMX

DC

DC

ON

LF

RE

DN

LU

APMX









Order Number No.F

Stoc

k*

* Number of Flutes


Corner radius end mill, Short cut length, 3 flute, with multiple internal through coolant holes

CurvedEdge

a

a

Stability and reliability even when slotting, ramping and plunging.The cross sectional geometry of the flutes is perfect for efficient chip discharge.

12<DCON<16 20<DCON<25

Cutting Dia.Corner RadiusDepth of Cut Max.Usable Length

Neck Dia.Functional LengthConnection Dia.

10

12 1240 33000 15000 6 1216 1660 33000 20000 8 1620 2070 33000 26000 10 2025 2590 33000 32000 12.5 25

12 600 16000 7200 6 1216 600 12000 7200 8 1620 600 9500 7400 10 2025 600 7600 7300 12.5 25

12 1240 33000 15000 616 1660 33000 20000 820 2070 33000 26000 1025 2590 33000 32000 12.5

12 600 16000 7200 616 600 12000 7200 820 600 9500 7400 1025 600 7600 7300 12.5

y

y

y

y

(mm)

(mm)

(mm)

(mm)

A3SA/A3SARB, DLC3SA/DLC3SARB

DC

DC

ap

ap

ae

ae

ap

ap

Note 1) It is recommended to use a water-soluble coolant. It is also possible to use air blow (external/internal) for DLC coated types.Note 2) Climb milling is recommended for side cutting.Note 3) This table shows the cutting condition with less than 4D overhang length. If more than 4D, spindle speed, feed rate and depth of cut

should be reduced.Note 4) When ramping, consider the chip discharge and use a feed rate 50% lower than the slotting conditions above and also use a ramping

angle of 5º or less. Note 5) If the rigidity of the machine or the workpiece materials installation is very low, or chattering and noise are generated, reduce the

revolution and feed rate proportionately within the range described in the above table, or reduce the depth and width of cut.

DC:Cutting Dia.

DC:Cutting Dia.

Side Milling

Side Milling

Slot Milling

Slot Milling

WorkpieceMaterial Aluminium Alloys




Recommended Cutting ConditionsUse high efficiency cutting conditions when the machine and workpiece rigidity, and chip evacuation properties are sufficient.Use lower, general-purpose cutting conditions when the mechanical or workpiece rigidity or chip evacuation porperties are insufficient.

High Efficiency Conditions

General-purpose Conditions

Dia.DC

Cutting Speed(m/min)

Revolution(min-1)

Feed Rate(mm/min)

Depth of Cutae(mm)

Depth of cutap(mm)

Depth ofCut

Dia.DC


Revolution(min-1)

Feed Rate(mm/min)

Depth of Cutae(mm)

Depth of cutap(mm)

Depth ofCut

Dia.DC


Revolution(min-1)

Feed Rate(mm/min)

Depth of Cutap(mm)

Depth ofCut

Dia.DC


Revolution(min-1)

Feed Rate(mm/min)

Depth of Cutap(mm)

Depth ofCut

MITSUBISHI MATERIALS CORPORATION

Overseas Sales Dept, Asian RegionKFC bldg., 8F, 1-6-1 Yokoami, Sumida-ku, Tokyo 130-0015, JapanTEL +81-3-5819-8771 FAX +81-3-5819-8774

Overseas Sales Dept, European & American RegionKFC bldg., 8F, 1-6-1 Yokoami, Sumida-ku, Tokyo 130-0015, JapanTEL +81-3-5819-8772 FAX +81-3-5819-8774

2020.9.( - )EXP-20-E007

http://www.mitsubishicarbide.com/en/(Tools specifications subject to change without notice.)

For Your SafetyaDon't handle inserts and chips without gloves. aPlease machine within the recommended application range and exchange expired tools with new ones in advance of breakage. aPlease use safety covers and wear safety glasses. aWhen using compounded cutting oils, please take fire precautions. aWhen attaching inserts or spare parts, please use only the correct wrench or driver. aWhen using rotating tools, please make a trial run to check run-out, vibration and abnormal sounds etc.

Cutting Example

<Cutting Conditions>Workpiece Material : A7050Tool : A3SARB250R300N55C DC = ø25 mm, RE=3.0mmSpindle Revolution : 33000min-1 Cutting Speed : vc = 2600m/minFeed Rate : f = 25000mm/min Feed : fz = 0.25mm/t. Depth of Cut : ap = 16mm, ae=25mmCutting Mode : Internal Coolant (Water-soluble Coolants)Machine : For machining aluminium

structural parts for aircraft High-speed, high-output horizontal 5-axis M/C

Machining with a High-speed, High-output Horizontal 5-axis Machining CentreUltra-high efficiency processing was achieved with a stable chip discharge and no chattering.Metal Removal Rate of 10,000 cm3/min.

high efficiency. multi-functional machining of aluminium

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